This document summarizes opportunities for waste minimization and energy conservation in gelatin production through cleaner production methods. It discusses the current gelatin production process and identifies several stages where cleaner production options could provide environmental and economic benefits. These include using smaller raw material sizes to speed up processes, reusing waste water, optimizing filtration equipment, and directly packaging gelatin to reduce storage needs. Adopting these cleaner production methods could conserve significant amounts of water, energy and resources while also reducing costs during gelatin production.

1. IJSRD - International Journal for Scientific Research & Development| Vol. 2, Issue 08, 2014 | ISSN (online): 2321-0613
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Waste minimization and energy conservation in gelatin production by
raw material size minimization
Ghatna Trivedi1
1
M.E. [Environmental Management] Student
1
Department of Envoirnmental Engineering
1
L.D. College of Engineering, Ahmedabad, Gujarat
Abstract— Based on current manufacturing system of
gelatin production, cleaner production opportunities are
discussed considering aspect such as waste minimization,
energy conservation, etc. Improving the utilization of inputs
and minimizing the production of unwanted or low value
outputs is fundamental to improving profitability. Adopting
cleaner production also helps in awareness of consequences
of environmental practices that are unfriendly and that are
detrimental to the industry’s bottom-line. Adopting cleaner
production may require onetime investment or it can be
done with zero cost. A few process changes and good
housekeeping in production of gelatin may increase gelatin
yield and reduces wastewater quantity. Process changes
such as automatic handling of machines, direct packaging
etc leads to environmental as well as financial benefits.
Byproduct utilization and wastewater reuse are other
benefits of cleaner production. This paper discuss about
current process followed in gelatinization, suggestion of
cleaner production opportunities throughout the process and
cost benefit analysis for suggested cleaner production
opportunities. Major advantages from cleaner production in
gelatinization here is byproduct reuse and waste water
reutilization.
Keywords: Cleaner production, Gelatinization, Waste
minimization and reuse
I. INTRODUCTION
Cleaner production is the maximum feasible reduction of all
waste generated at production sites. It involves judicious use
of resources through source reduction, reuse of material,
water conservation; energy efficiency etc. preventing or
recycling at the source eliminates the need for off-site
recycling or treatment. Pollutant elimination at or near the
source is typically less expensive than collecting, treating
and disposal. Cleaner production facilitates energy
conservation and raw material, cost reduction, ,
environmentally sound process, increased efficiency , etc.
Gelatin (word derived is from Latin word
‘gelatus’= frozen), it contains 80-90% protein and is used
extensively in the metal refining, food and photographic
industry, also in such diverse industries as cosmetics, paper,
plastics, pharmaceutical and toiletries. The raw material for
gelatin is the collagen, naturally occurring protein, which is
sourced from meat industry. From its earliest uses, when
boiled up into broth, which when cooled produced a
nutritious jelly, gelatin. Like its raw material, collagen,
gelatin is made up of many different amino acids which are
the building blocks of all proteins. Bloom value is a measure
of the gel strength of a particular type of gelatin indicating
the firmness of the gel. Different bloom strengths are
required for different applications and must be considered
together with other performance characteristics when
selecting a suitable grade of gelatin.
Methodology followed for research work has been
done with Literature survey in order to understand the
cleaner production methods and tools. It also helps to
understand research work done previously. It also helps in
understanding different types of plans or the strategies for
abatement or reduction of waste from the process. Primary
survey is done to know about existing manufacturing
process and its efficiency , generation of waste , utilities
required , second is to do questionnaire survey in plant and
Secondary data collection to obtain information about per
day production, electricity consumption , waste generation
(overall as well as in each step),material consumption,
method of disposal , financial condition, present manpower ,
equipment, etc. To obtain result Compilation of data is done
and associating it in order to compare the data before and
after cleaner production.
II. INDUSTRY PROFILE
Industry studied for the research produces gelatin with
specific bloom strengths suited to a variety of applications in
the pharmaceutical and food industry. Gelatins are suitable
for a variety of uses in the pharmaceutical industry,
including hard and soft shell capsules; vitamin
encapsulation, tablet binding and others. Product Ranges
offered limed processed (Type B) Pharmaceutical gelatins
with Bloom gel strengths ranging from 150 to 270.
A. Gelatinization
Pretreatment includes cleaning of raw material, based on
type of raw materials two type of process followed to make
gelatin- in acid process The raw material ( pigskin) is
subjected to a 24-h conditioning process. This involves
treatment with acid. After this,
PHYSICAL
CHARACTERISTICS
Appearance
Colorless or pale yellow
powder or granules
Bloom % ±10g
Moisture % Max 13
Ash % Max 2
pH 5-6.5
CHEMICAL
CHARECTERISTICS
Arsenic in ppm Max 1
Lead Max 1
Copper Max 3
Zinc Max 100
So2 Max 1000
MICROBIOLOGICAL
CHARACTERISTICS

2. Waste minimization and energy conservation in gelatin production by raw material size minimization
(IJSRD/Vol. 2/Issue 08/2014/057)
All rights reserved by www.ijsrd.com 250
Total count Max 1000
Salmonellae in 10g Absent
Coliforms in 0.1g Absent
Table 1: Typical specifications
the gelatin can be extracted. Where as in Alkaline
process the raw material (bovine hide) is subjected to
several weeks of treatment with alkali. This enables the
collagen structure to be gently transformed. The collagen it
contains, now softened by the pretreatment, can now be
extracted using warm water. The raw materials are then
treated with warm water, the gelatin being removed in a
number of process steps in contaminated form. The first
gelatin extracts, obtained at relatively low temperatures, are
firm and have a light color compared to final product. The
extraction solutions contain approximately 6 % gelatin.
After these first extracts, the remaining material is treated
with fresh water, at a higher temperature compared to
previous step. This sequence is continued until all the
gelatin has been extracted into solution. A variation of this
classical extraction process is the so-called continuous
process. The desired properties of the gelatin can be
adjusted by means of temperature and Ph. The gelatin
solution obtained from the extraction process is placed in
high-performance separators where it is freed from residual
traces of fat from the raw material and from any insoluble
particles. Precoat filters are then employed to remove fine-
particle contamination with the help of ultrafilteration
process, followed by ion exchange process. Purification of
the gelatin is completed by removing any salts present using
an ion exchange process. Plate and frame filter with manual
operation is also used to get the concentrate. In the
concentration step, multi-stage vacuum evaporators are used
to remove part of the water from the dilute gelatin extraction
solution in a gentle process. In this way, the gelatin becomes
viscous, highly viscous solution is then passed through
polishing filters made of cellulose plates; these remove the
very finest of particles that may remain. Noodles of liquid
gelatin is now formed. Subsequent to the concentration step,
the gelatin solution is heat-sterilized for safety purposes; it is
then cooled and set. The gelatin is now in the form of gelatin
noodles; these are then run onto a enclosed conveyor belt of
a dryer. Here, the gelatin is dried. At the end of the drier, the
now hard and brittle gelatin is broken up and stored in the
warehouse until required for further use. Individual batches
are only released for further use on the successful
completion of physical, chemical and biological testing in
the lab. Gelatin is packed in multiply paper sacks, all
containing a polythene liner. Gelatins should be stored in the
sealed containers in cold dry conditions away from
odoriferous materials. Under such conditions, gelatins are
generally considered to be stable almost indefinitely.
III. CLEANER PRODUCTION OPTIONS
After studying entire process of gelatin production cleaner
production options are generated at several stages for
environmental and economic benefits. At primary stage of
process, bone washing is done which requires large quantity
of water. Waste water produced at other steps can be used
again for bone washing as it does not required standard
quality of water. Raw material minced smaller than usual
can speed up process at every stage. After extraction phase
in the process, by product produced has property like
dichlorophosphate, hence it can be used as animal feed.
Industry uses 4 manual filter press, for which flow rate of
filtrate is less instead use of 2 filter press at a time can
increase the flow rate and pressure required for filtration can
also be increased. Waste water in huge quantity is generated
in settling stage, filtration process, and evaporation. At first
stage of evaporation only 6% of gelatin is retrieved and then
it is followed by second stage of evaporation. Instead if
waste water generated at each stage of process is sent back
to settling again, more amount of gelatin can be regained.
Effluent discharge practice at each stage can be done by
practicing controlling spills at filtration stage, draining of
pipe before cleaning and use of automatic shutoff systems
which can result in BOD reduction in waste water and
Reduced trade waste discharge volume and loading. Storage
of gelatin noodles and gelatin granules require cold and dry
condition. After formation of gelatin, it is stored in ware
house where cold and dry condition for quality of gelatin is
maintained, instead of open storage of gelatin it can be
directly packed in to desired quantity.
Per day production 7-8 tons
Wash water requirement 8.5 m3
/ton
Total waste water produced per ton
gelatin
2000-3000 tons
Byproduct produced Dichlorophosphate
Process type continuous
Electricity consumption per day 45Kwh
Table 2: production details
IV. RESULT
Result obtained from process study and cleaner Production
suggestions showed that there can be huge conservation of
energy and water by adopting simple cleaner production
methods. In many stages such as filtering there can be
reduction in cost too. For example if instead of 4 filter press
only 2 is used according to need, it saves amount of 2 filter
press as well as energy required for it is conserved. In
preliminary stage of mincing of raw material when it is
minced to very small size than usual, time require for
washing and mincing reduced to 1-4 hours instead of 10-60
hours hence energy required in case of the process for such
long duration has been reduced to more than 10%. Waste
water is used again for washing, BOD reduction; proper
handling of effluent discharge time and energy in waste
water treatment is conserved. Gelatin is stored in cold, dry
condition so when it is directly packed cost of storage and
maintenance of specific condition is saved.
Condition
before CP
CP Options
Environmental
benefit
Mincing of
raw material
Mincing in very
small size
Conservation of water
up to 5 m3
/ton,
residue after
extraction is
negligible
Fresh water
used for bone
washing
Use of waste
water for bone
washing
Conservation of fresh
water and reduced
quantity of waste
waster
Total 4 filter
press used
with low flow
Use of 2 filter
press for filtering
Conservation of
energy and increased
efficiency.

3. Waste minimization and energy conservation in gelatin production by raw material size minimization
(IJSRD/Vol. 2/Issue 08/2014/057)
All rights reserved by www.ijsrd.com 251
rate and
pressure.
Waste water at
each stage is
discharged as
effluent.
Waste water at
each stage is fed
back to settling
tank for
retrieving gelatin
out of it.
BOD reduction in
waste water.
Effluent
discharge
Spill control,
drainage of pipe
adopted.
Clean process
Storage of
gelatin at cold,
dry condition
in ware house
Direct packaging
of gelatin.
Conservation of
energy and reduced
wastage of product in
in-house
transportation.
V. CONCLUSION
The adoption of simple techniques without many changes in
process and without cost involvement can also lead to
environmental and economical benefits. From study
conducted above it is concluded that small process change
where waste minimization and energy conservation can lead
to major benefits such as reduction in BOD in waste water,
controlled use of water, limited use of electricity, increased
efficiency, reduced process time, etc. hence in gelatin
industry adoption of feasible cleaner production
opportunities helps in improvisation.
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